MULTIQUIP DCA400SSK, DCA-400SSK, DCA-400SSV User manual

  • Hello! I am an AI chatbot trained to assist you with the MULTIQUIP DCA400SSK User manual. I’ve already reviewed the document and can help you find the information you need or explain it in simple terms. Just ask your questions, and providing more details will help me assist you more effectively!
MQ POWER
DCA-400SSK
DCA-400SSK2
WHISPERWATT
TM
GENERATOR
(STANDARD)
PARTS AND OPERATION MANUAL
Revision #3 (09/17/01)
MULTIQUIP INC. PARTS DEPARTMENT:
18910 WILMINGTON AVE. 800-427-1244
CARSON, CALIFORNIA 90746 FAX: 800-672-7877
310-537-3700
SERVICE DEPARTMENT:
800-421-1244 800-835-2551
FAX: 310-537-3927 FAX: 310-638-8046
E-mail:[email protected] www:multiquip.com
© COPYRIGHT 2001, MULTIQUIP INC.
PARTS LIST NO. C3875300104B
S/N UP TO 3701676-400SSK
S/N3101677~ 400SSK2
PAGE 2 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)
DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 3
HERE'S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL NUMBER
ON-HAND WHEN CALLING
PP
PP
P
ARAR
ARAR
AR
TS DEPTS DEP
TS DEPTS DEP
TS DEP
ARAR
ARAR
AR
TMENTTMENT
TMENTTMENT
TMENT
800/427-1244 or 310/537-3700
FAX: 800/672-7877 or 310/637-3284
SERSER
SERSER
SER
VICE DEPVICE DEP
VICE DEPVICE DEP
VICE DEP
ARAR
ARAR
AR
TMENTTMENT
TMENTTMENT
TMENT
800/835-2551 or 310/537-3700
FAX: 310/638-8046
WW
WW
W
ARRANTY DEPARRANTY DEP
ARRANTY DEPARRANTY DEP
ARRANTY DEP
ARAR
ARAR
AR
TMENTTMENT
TMENTTMENT
TMENT
800/835-2551 or 310/537-3700
FAX: 310/638-8046
MAINMAIN
MAINMAIN
MAIN
800/421-1244 or 310/537-3700
FAX: 310/537-3927
PAGE 4 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)
Here's How To Get Help .............................................3
Table Of Contents ......................................................4
Rules For Safe Operation ...................................... 6-9
Towing ......................................................................10
Trailer Safety Guidelines .................................... 11-17
Trailer Wiring Diagram..............................................18
Electric Brake Troubleshooting.................................19
Hydraulic Brake Troubleshooting .............................20
Operation And Safety Decals ............................. 21-22
Specifications ...........................................................23
General Information ........................................... 24-25
Major Components ..................................................26
Dimensions (Top, Side And Rear)...................... 28-29
Control Panel ...................................................... 30-31
Engine Operating Panel ..................................... 32-33
Output Terminal Panel Overview ........................ 34-39
Installation .......................................................... 40-41
Pre-Setup ........................................................... 42-45
Load Application ...................................................... 46
Generator Start-Up Procedure (Key Switch) ..... 47-50
Generator Start-Up Procedure (Controller) .............51
Generator Shut-Down Procedure ............................52
Maintenance ...................................................... 54-57
Generator Wiring Diagram .......................................58
Engine Wiring Diagram ............................................60
Troubleshooting (Engine) ................................... 62-63
Troubleshooting (Generator) ...................................64
Troubleshooting (Engine Controller) ........................65
Explanation Of Codes In Remarks Column .............66
Suggested Spare Parts ............................................67
TABLE OF CONTENTS
NOTE
Specification and part numberSpecification and part number
Specification and part numberSpecification and part number
Specification and part number
are subject to change withoutare subject to change without
are subject to change withoutare subject to change without
are subject to change without
noticenotice
noticenotice
notice
..
..
.
MQ Power DCA-400SSK
AC Generator
Generator Assembly .......................................... 68-71
Control Box Assembly ........................................ 72-75
Engine Radiator Assembly ................................. 76-79
Engine Operating Panel Assembly .................... 80-81
Output Terminal Assembly ................................. 82-83
Battery Assembly ............................................... 84-85
Actuator Assembly ............................................. 86-87
Muffler Assembly ............................................... 88-89
Fuel Tank Assembly ........................................... 90-91
Enclosure #1 Assembly...................................... 92-95
Enclosure #2 Assembly...................................... 96-99
Enclosure #3 Assembly........................................ 100-
103
Enclosure (Rubber Seals) .............................. 104-105
Oil Piping Assembly ....................................... 106-107
Name Plate and Decals ................................. 108-111
Terms and Conditions Of Sale — Parts ................ 112
DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 5
PARTS ORDERING PROCEDURES
Get special freight allowances
when you order 10 or more
line items via FAX!**
UPS Ground Service at no charge for freight
PS Third Day Service at one-half of actual freight cost
No other allowances on freight shipped by any other carrier.
**Common nuts, bolts and washers (all items under $1.00 list price)
do not count towards the 10+ line items.
*DISCOUNTS ARE SUBJECT TO CHANGE*
Fax order discount and UPS special programs revised June 1, 1995
For faxed orders only
UPS
Special
Earn Extra Discounts when
you order by FAX!
All parts orders which include complete part numbers
and are received by fax qualify for the following extra
discounts:
Number of
line items ordered Additional Discount
1-9 items 3%
10+ items** 5%
Now! Direct TOLL-FREE access
to our Parts Department!
Toll-free nationwide:
800-421-1244
Toll-free FAX:
800/6-PARTS-7 • 800-672-7877
Dealer account number
Dealer name and address
Shipping address (if different than billing address)
Return fax number
Applicable model number
Quantity, part number and description of each part
Specify preferred method of shipment:
UPS Ground
UPS Second Day or Third Day*
UPS Next Day*
Federal Express Priority One (please provide us with your Federal
Express account number)*
Airborne Express*
Truck or parcel post
*Normally shipped the same day the order is received, if prior to 2PM west coast time.
Extra Fax Discount
for Domestic USA
Dealers Only
PAGE 6 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)
RULES FOR SAFE OPERATION
NEVER touch the hot exhaust
manifold, muffler or cylinder. Allow
these parts to cool before servicing
engine or generator.
The engine of this generator requires an adequate free
flow of cooling air. Never operate the generator in any
enclosed or narrow area where free flow of the air is
restricted. If the air flow is restricted it will cause serious
damage to the generator or engine and may cause injury
to people. The generator engine gives off DEADLY carbon
monoxide gas.
High Temperatures Allow the
engine to cool before adding fuel or performing service
and maintenance functions. Contact with
hot
components
can cause serious burns.
CAUTION:
Failure to follow instructions in this manual
may lead to serious injury or even death!
This equipment is to be operated by trained
and qualified personnel only! This equipment
is for industrial use only.
The following safety guidelines should always be used when
operating the DCA-400SSK portable generator:
GENERAL SAFETY
DO NOT operate or service this equipment before
reading this entire manual.
This equipment should not be operated by
persons under 18 years of age.
NEVER operate this equipment without
proper protective clothing, shatterproof
glasses, steel-toed boots and other
protective devices required by the job.
NEVER operate this equipment when not feeling
well due to fatigue, illness or taking medicine.
NEVER operate this equipment under the
influence or drugs or alcohol.
NEVER use accessories or attachments, which are not
recommended by MQ Power for this equipment. Damage
to the equipment and/or injury to user may result.
Manufacturer does not assume responsibility for any
accident due to equipment modifications.
Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.
Always check the machine for loosened threads or bolts
before starting.
CAUTION
:
Always use extreme caution when
working with flammable liquids. When
refueling, stop the engine and allow it
to cool. DO NOT smoke around or near
the machine. Fire or explosion could
result from fuel vapors, or if fuel is
spilled on a hot engine.
NEVER operate the generator in an
explosive atmosphere or near combustible materials. An
explosion or fire could result causing severe
bodily harm
or even death.
Topping-off to filler port is dangerous, as it tends to spill
fuel.
Always refuel in a well-ventilated area,
away from sparks and open flames.
DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 7
RULES FOR SAFE OPERATION
CAUTION
:
Backfeed to a utility system can cause electrocution and/
or property damage. Do not connect to any building's
electrical system except through an approved device or
after building main switch is opened.
Never use damaged or worn cables when
connecting power tools or equipment to the
generator. Make sure power connecting
cables are securely connected to the
generators output terminals, insufficient
tightening of the terminal connections may
cause damage to the generator and
electrical shock.
CAUTION
:
DO NOT touch or open any of the below
mentioned components while the
generator is running. Always allow
sufficient time for the engine and generator
to cool before performing maintenance.
Radiator
1. Radiator Cap - Removing the radiator cap while the
engine is hot, will result in high pressurized, boiling
water to spew out of the radiator, causing severe
scalding to any persons in the general area of the
generator.
2. Coolant Drain Plug - Removing the coolant drain
plug while the engine is hot will result in hot coolant
to flow out of the coolant drain plug, therefore causing
severe scalding to any persons in the general area
of the generator.
3. Engine Oil Drain Plug - Removing the engine oil
drain plug while the engine is hot will result in hot oil
to flow out of the oil drain plug, therefore causing
severe scalding to any persons in the general area
of the generator.
CAUTION
:
CAUTION
:
NEVER touch output terminals during operation. This is
extremely dangerous.
Always stop the machine when
contact with the output terminals.
PAGE 8 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)
RULES FOR SAFE OPERATION
NEVER Run engine without air filter. Severe engine
damage may occur.
Always service air cleaner frequently to prevent
carburetor malfunction.
Always disconnect the battery before performing service
on the generator.
Always be sure the operator is familiar with proper safety
precautions and operations techniques before using
generator.
Always store equipment properly when not in use.
Equipment should be stored in a clean, dry location out
of the reach of children.
DO NOT leave the generator running in the manual mode
unattended.
DO NOT allow unauthorized people to operate this
equipment.
Always read, understand, and follow procedures in
Operators Manual before attempting to operate
equipment.
Refer to the
KK
KK
K
omatsu Engine Owner's Manomatsu Engine Owner's Man
omatsu Engine Owner's Manomatsu Engine Owner's Man
omatsu Engine Owner's Man
ualual
ualual
ual
for
engine technical questions or information.
Loading and Unloading (Crane)
Before lifting, make sure the generator's lifting hook is
secure and that there is no apparent damage to the
generator itself (loose screws, nuts and bolts). If any
part is loose or damaged, please take corrective action
before lifting.
Always drain fuel prior to lifting.
Make sure the crane or lifting device has been properly
secured to the hook of guard frame on generator.
NEVER lift the machine while the engine is running.
Use adequate lifting cable (wire or straps) of sufficient
strength.
When lifting the generator, always use the balanced
center-point suspension hook and lift straight upwards.
NEVER allow any person or animal to stand underneath
the machine while lifting.
When loading the generator on a truck, be sure to use
the front and back frame bars as a means to secure
the generator during transport.
Battery
Never over fill the battery with water above
the upper limit.
CAUTION
:
The battery contains acids that can cause injury to the
eyes and skin. To avoid eye irritation, always wear safety
glasses. Use well insulated gloves when picking up the
battery. Use the following guidelines when handling the
battery:
1. DO NOT drop the battery. There is the possibility of risk
that the battery may explode.
2. DO NOT expose the battery to open flames, sparks,
cigarettes etc. The battery contains combustible gases
and liquids. If these gases and liquids come in contact
with a flame or spark, an explosion could occur.
3. Always keep the battery charged. If the battery is not
charged a buildup of combustible gas will occur.
4. Always keep battery charging and booster cables in good
working condition. Repair or replace all worn cables.
5. Always recharge the battery in an open air environment,
to avoid risk of a dangerous concentration of combustible
gases.
6. In case the battery liquid (dilute sulfuric acid) comes in
contact with
clothing or skinclothing or skin
clothing or skinclothing or skin
clothing or skin
, rinse skin or clothing
immediately with plenty of water.
7. In case the battery liquid (dilute sulfuric acid) comes in
contact with your eyes, rinse eyes immediately with
plenty of water, then contact the nearest doctor or hospital,
and seek medical attention.
DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 9
Transporting
Always shutdown engine before transporting.
Tighten fuel tank cap securely.
Drain fuel when transporting generator over long distances
or deteriorated roads.
Always tie-down the generator during transportation by
securing the generator.
If generator is mounted on a trailer, make sure trailer
complies with all local and state safety transportation
laws. See page 10 for basic towing procedures.
Emergencies
Always know the location of the nearest
fire extinguisherfire extinguisher
fire extinguisherfire extinguisher
fire extinguisher
and
first aid kitfirst aid kit
first aid kitfirst aid kit
first aid kit
. Know the location of the nearest telephone.
Also know the phone numbers of the nearest
ambulanceambulance
ambulanceambulance
ambulance
,
doctordoctor
doctordoctor
doctor
and
fire departmentfire department
fire departmentfire department
fire department
.
Maintenance Safety
NEVER lubricate components or attempt service on a
running machine.
Always allow the machine a proper amount of time to
cool before servicing.
Keep the 0in proper running condition.
Fix damage to the machine immediately and always
replace broken parts.
Dispose of hazardous waste properly. Examples of
potentially hazardous waste are used motor oil, coolant,
fuel, and fuel filters.
DO NOT use plastic containers to dispose of hazardous
waste.
DO NOT pour waste, oil, coolant or fuel directly onto the
ground, down a drain or into any water source
RULES FOR SAFE OPERATION
PAGE 10 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)
To reduce the possibility of an accident while transporting
the generator on public roads, always make sure the trailer
(Figure 1) that supports the generator and the towing vehicle
are in good operating condition and both units are
mechanically sound.
The following list of suggestions should be used when towing
your generator:
CAUTION :
Towing Safety Precautions
ALWAYS attach trailer's safety chain to bumper of towing
vehicle.
ALWAYS make sure the vehicle and trailer directional,
backup, brake, and trailer lights are connected and
working properly.
The maximum speed unless otherwise posted for highway
towing is 55 MPH. It is not recommended for off-road
towing. However, if necessary, do not exceed 15 MPH
or less depending on type of terrain to prevent damage
to the axles.
Place
chocked blocks
underneath wheel to prevent
rollingrolling
rollingrolling
rolling,
while parked.
Place
support blocks
underneath the trailer's bumper to
prevent
tippingtipping
tippingtipping
tipping
, while parked.
Use the trailer's hand winch to adjust the height of the
trailer, then insert locking pin to lock wheel stand in place,
while parked.
Avoid sudden stops and starts. This can cause skidding,
or jackknifing. Smooth, gradual starts and stops will
improve gas milage.
Avoid sharp turns to prevent rolling.
Remove wheel stand when transporting.
DO NOT transport generator with fuel in tank.
Check with your county or state safety
towing regulations department before
towing your generator.
Make sure the hitch and coupling of the towing vehicle
are rated equal to, or greater than the trailer "gross vehicle
weight rating" (GVWR).
ALWAYS inspect the hitch and coupling for wear. NEVER
tow a trailer with defective hitches, couplings, chains
etc.
Check the tire air pressure on both towing vehicle and
trailer. Also check the tire tread wear on both vehicles.
ALWAYS make sure the trailer is equipped with a "Safety
Chain".
Figure 1. Generator with Trailer
DCA-400SSK — TOWING
DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 11
Explanation of Chart:
This section is intended to provide the user with trailer ser-
vice and maintenance information. The service and mainte-
nance guidelines referenced in this section apply a wide range
of trailers. Remember periodic inspection of the trailer will
ensure safe towing of the equipment and will prevent dam-
age to the equipment and personal injury.
It is the purpose of this section to cover the major mainte-
nance components of the trailer. The following trailer com-
ponents will be discussed in this section:
Brakes
Tires
Lug Nut Torquing
Suspension
Electrical
Brake Troubleshooting Tables
Use the following definitions with reading Table 1.
1. Fuel Cell - Provides an adequate amount of fuel for
the equipment in use. Fuel cells must be empty when
transporting equipment.
2. Braking System - System employed in stopping the
trailer. Typical braking systems are electric, surge, hy-
draulic, hydraulic-surge and air.
3. GVWR- Gross Vehicle Weight Rating (GVWR), is the
maximum number of pounds the trailer can carry, in-
cluding the fuel cell (empty).
DCA-400SSK — TRAILER-SAFETY GUIDELINES
4. Frame Length - This measurement is from the ball
hitch to the rear bumper (reflector).
5. Frame Width - This measurement is from fender to
fender.
6. Jack Stand - Trailer support device with maximum
pound requirement from the tongue of the trailer.
7. Coupler - Type of hitch used on the trailer for towing.
Usually consists of chains and ball or eye.
8. Tire Size - Indicates the diameter of the tire in inches
(10,12,14, etc.), and the width in millimeters
(175,185,205, etc.). The tire diameter must match the
diameter of the tire rim.
9. Tire Ply - The tire ply (layers) number is rated in
letters; 2-ply,4-ply,6-ply, etc.
10. Wheel Hub - The wheel hub is connected to the
trailers axle.
11. Tire Rim - Tires mounted on a tire rim. The tire rim must
match the size of the tire.
12. Lug Nuts - Used to secure the wheel to the wheel hub.
Always use a torque wrench to tighten down the lug
nuts. See Table 4 and Figure 5 or lug nut tightening and
sequence.
13. Axle - Indicates the maximum weight the axle can sup-
port in pounds, and the diameter of the axle expressed
in inches (see Table 3). Please not that some trailers
have a double axle. This will be shown as 2-6000 lbs.,
meaning two axles with a total weight capacity of 6000
pounds.
14. Suspension - Protects the trailer chassis from shocks
transmitted through the wheels. Types of suspension
used are leaf, Q-flex, and air ride.
15. Electrical - Electrical connectors (looms) are provided
with the trailer so the brake lights and turn signals can
be connected to the towing vehicle.
16. Application - Indicates which units can be employed
on a particular trailer.
CAUTION:
ALWAYS make sure the trailer is in good
operating condition. Check the tires for
proper inflation and wear. Also check the
wheel lug nuts for proper tightness.
PAGE 12 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)
snoitacificepS.1elbaT
LEDOM NOITACILPPA LLECLEUF METSYSEKARB RWVG EMARF
HTGNEL
EMARF
HTDIW
KCAJ
DNATS
W01-RLRT
,522WDS
003WLT,052WGS
ONONSBL0091"69"05.BL008
LEEHWTLITLLUF
01-RLRT
-ACD,21GLT,01ACD
51
ONONSBL0091"69"05.BL008
LEEHWTLITLLUF
FX01-RLRT
,21-GLT,01ACD
003-WLT,51ACD
LAG25ONSBL0091"69"05.BL008
LEEHWTLITLLUF
W522-RLRT
,SREDLEW
SS0007AD
ONONSBL0022"58"24.BL008
LEEHWTLITLLUF
004WLB-RLRT
004-WLBONCIRTCELESBL0072"451TSAM/W
"421O/W
"55
)LLAT"87(
.BL008
LEEHWTLITLLUF
X05-RLRT
52-ACDONONSBL0072"421"55.BL008
LEEHWTLITLLUF
FX05-RLRT
52-ACDLAG14ONSBL0072"421"55.BL008
LEEHWTLITLLUF
W07-RLRT
07,06-,54-ACDONEGRUSSBL0007"681"77.BL0002
DAPTALF
X07-RLRT
07,06-,54-ACDTPOEGRUSSBL0007"831"66.BL0002
DAPTALF
FX07-RLRT
07,06-,54-ACDLAG35EGRUSSBL0007"831"66.BL0002
DAPTALF
FX001-RLRT
521,001-ACDLAG051EGRUSCILUARDYHSBL0007"091"67.BL0002
DAPTALF
521/58-RLRT
521,001,58-ACDLAG541CILUARDYHSBL00001"681"77.BL0002
DAPTALF
FX051-RLRT
081,051-ACDLAG002EGRUSCILUARDYHSBL06111"402"48.BL0005
DAPTALF
FX022-RLRT
022-ACDLAG052EGRUSCILUARDYHSBL00041"222"38.BL0005
DAPTALF
FX003-RLRT
003-ACDLAG052EGRUSCILUARDYHSBL00081"832"38.BL0005
DAPTALF
FX004-RLRT
004-ACDLAG053CIRTCELESBL00081"832"38.BL0005
DAPTALF
FX006-RLRT
008,006-ACDLAG055RIASBL00003"483"69.BL0005
DAPTALF
XS008-RLRT
008,006-ACDLAG055RIASBL00003"483"69.BL0005
DAPTALF
DCA-400SSK — TRAILER-SPECIFICATIONS
DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 13
)t'noC(snoitacificepS.1elbaT
LEDOM RELPUOC SERIT SLEEHW ELXA SBUH NOISNEPSUS LACIRTCELE
W01-RLRT
SSALCLLAB"2
ELBATSUJDA2
C31-571"05.4X"312X2#0022GUL5FAEL3/WMOOLERIW4
TALFELOP4
01-RLRT
SSALCLLAB"2
ELBATSUJDA2
C31-571"5.4X"312X2#0022GUL5FAEL3TALFELOP4
FX01-RLRT
SSALCLLAB"2
ELBATSUJDA2
C31-571"5.4X"312X2#0022GUL5FAEL3TALFELOP4
W522-RLRT
SSALCLLAB"2
ELBATSUJDA2
B31-571"5.4X312X2#0022GUL5XELFQTALFELOP4
004WLB-RLRT
SSALCLLAB"2
ELBATSUJDA2
C31-571"5.4X312X2#0022GUL5FAEL3TALFELOP4
X05-RLRT
SSALCLLAB"2CRL31-87B"05.4X"31.sbl0053
"8/3-2
GUL5FAEL4TALFREBBURELOP4
FX05-RLRT
SSALCLLAB"2CRL31-87B"05.4X"31.sbl0053
"8/3-2
GUL5FAEL4TALFREBBURELOP4
W07-RLRT
SSALCLLAB"2
ELBATSUJDA"3
C41-502
)4(SAIB
"5X"41.sbl0053
"3
GUL5FAEL5TALFREBBURELOP4
X07-RLRT
SSALCLLAB"2
ELBATSUJDA"3
C41-502
)4(SAIB
"5X"41sbl0053
"3
GUL5FAEL5TALFREBBURELOP4
FX07-RLRT
SSALCLLAB"2
ELBATSUJDA"3
C41-502
)4(SAIB
"5X"41.sbl0053
"3
GUL5FAEL5TALFREBBURELOP4
FX001-RLRT
TPO6/5-2ELBATSUJDA
EYE"3
C51-502
)4(SAIB
"5.5X"41sbl0053
"3
GUL5FAEL5MOOLERIW4
521/58-RLRT
TPO6/5-2ELBATSUJDA
EYE"3
D51R57/522TS
)4(LAIDAR
"6x"41sbl0006-)2(GUL6FAEL7MOOLERIW4
FX051-RLRT
EYELLAB"3E61-057
)4(SAIB
"7X"61sbl0006-)2(GUL8FAEL7MOOLERIW4
FX022-RLRT
ELBATSUJDAEYE"3E61R58/532TS
)4(LAIDAR
"7X"61sbl0007-)2(GUL8XELFQMOOLERIW4
FX003-RLRT
ELBATSUJDAEYE"3E61R58/532TS
)6(LAIDAR
"7X"61sbl0006-)2(GUL8XELFQMOOLERIW4
FX004-RLRT
ELBATSUJDAEYE"3E61R58/532TS
)6(LAIDAR
"7X"61.sbl0007-)3(GUL8XELFQMOOLERIW4
FX006-RLRT
LEEHWHT5H5.71R57/512TS
)8(LAIDAR
"7X"61sbl00001-)3(GUL8FAEL7MOOLERIW6
RA008-RLRT
LEEHWHT5H5.71R57/512TS
)8(LAIDAR
"7X"61sbl00001-)3(GUL8EDIR-RIAMOOLERIW6
DCA-400SSK — TRAILER-SPECIFICATIONS
PAGE 14 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)
DCA-400SSK — TRAILER SAFETY GUIDELINES
Brakes
If your trailer has a braking system, the brakes should be
inspected the first 200 miles of operation. This will allow the
brake shoes and drums to seat properly. After the first 200
mile interval, inspect the brakes every 3,000 miles. If driving
over rough terrain, inspect the brakes more frequently.
Electric Brakes
Electrically actuated brakes (Figure 2) are similar to hydraulic
brakes. The basic difference is that hydraulic brakes are
actuated by an electromagnet.
Listed below are some of the advantages that electric brakes
have over hydraulic brakes:
Brake system can be manually adjusted to provide the
corrected braking capability for varying road and load
conditions
Brake system can be modulated to provide more or less
braking force, thus easing the brake load on the towing
vehicle
Brake system has very little lag time between the time
the vehicles brakes are actuated and the trailers brakes
are actuated
Brake system can provide an independent emergency
brake system
Remember in order to properly synchronize the tow vehicles
braking to the trailers braking, can only be accomplished by
road testing. Brake lockup, grabbiness or harshness is due
to lack of synchronization between the tow vehicle and the
trailer being towed or under-adjusted brakes.
Before any brake synchronizations adjustments can be made,
the trailer brakes should be burnished-in by applying the
brakes 20-30 times with approximately a 20 m.p.h. decrease
in speed, e.g. 40 m.p.h. to 20 m.p.h. Allow ample time for
brakes to cool between application. This allows the brake
shoes to slightly be seated into the brake drum surface.
Figure 2 displays the major electric brake components that
will require inspection and maintenance. Please inspect these
components as required.
Electric Brake Adjustment
1. Place the trailer on jack stands. Make sure the jack
stands are placed on secure level ground.
2. Check the wheel and drum for free rotation.
3. Remove the adjusting hole cover from the adjusting slot
at the bottom brake backing plate.
4. With a screwdriver or standard adjusting tool, rotate the
star wheel of the adjuster assembly to expand the brake
shoes.
5. Adjust the brake shoes outward until the pressure of the
lining against the wheel drum makes the wheel difficult
to turn.
6. Rotate the star wheel in the opposite direction until the
wheel rotates freely with slight lining drag.
7. Replace the adjusting hole cover and lower the trailer to
the ground.
8. Repeat steps 1 through 6 on the remaining brakes.
DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 15
DCA-400SSK — TRAILER SAFETY GUIDELINES
Hydraulic/Air/Surge Brakes
Hydraulic brakes (Figure 3) should not require any special
attention with the exception of routine maintenance such as
shoe and lining replacement. These brakes can be adjusted
in the same manner as electric brakes. Brake lines should
be periodically checked for cracks, kinks, or blockage.
Figure 3 below displays the major hydraulic/air/surge brake
components that will require inspection and maintenance.
Please inspect these components as required using steps 1
through 6 as referenced in the electric brake adjustments
section.
Figure 2. Electrical Brake Components
Figure 3. Hydraulic Brake Components
PAGE 16 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)
Tires/Wheels/Lug Nuts
Tires and wheels are a very important and critical
components of the trailer. When specifying or replacing the
trailer wheels it is important the wheels, tires, and axle are
properly matched.
CAUTION:
DO NOT attempt to repair or modify a
wheel. DO NOT install in inner tube to
correct a leak through the rim. If the rim
is cracked, the air pressure in the inner
tube may cause pieces of the rim to
explode (break off) with great force and
cause serious eye or bodily injury.
Tire Wear/Inflation
Tire inflation pressure is the most important factor in tire life.
Pressure should be checked cold before operation DO NOT
bleed air from tires when they are hot. Check inflation
pressure weekly during use to insure the maximum tire life
and tread wear.
Table 2 (Tire Wear Troubleshooting) will help pinpoint the
causes and solutions of tire wear problems.
CAUTION:
NOTE
ALWAYS wear safety glasses when removing
or installing force fitted parts. Failure to comply
may result in serious injury.
DCA-400SSK — TRAILER SAFETY GUIDELINES
Figure 4. Major Suspension Components
Suspension
The leaf suspension springs and associated components
(Figure 4) should be visually inspected every 6,000 miles for
signs of excessive wear, elongation of bolt holes, and
loosening of fasteners. Replace all damaged parts
(suspension) immediately. Torqued suspension components
as detailed in Table 3.
DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 17
stnemeriuqeReuqroTnoisnepsuS.3elbaT
metI ).sbL-.tF(euqroT
TLOB-U"8/353-XAM03-NIM
TLOB-U"61/706-XAM54-NIM
TLOB-U"2/106-XAM54-NIM
SHACKLE BOLT
SPRING EYE BOLT
SNUG FIT ONLY
. PARTS MUST ROTATE FREELY. LOCKING
NUTS OR COTTER PINS ARE PROVIDED TO RETAIN NUT
-BOLT
ASSEMBLY
.
SHOULDER TYPE
SHACKLE BOLT
05-XAM03-NIM
stnemeriuqeReuqroTeriT.4elbaT
eziSleehWssaPtsriF
SBL-TF
ssaPdnoceS
SBL-TF
ssaPdrihT
SBL-TF
"2152-0204-5356-05
"3152-0204-5356-05
"4152-0206-05021-09
"5152-0206-05021-09
"6152-0206-05021-09
Lug Nut Torque Requirements
It is extremely important to apply and maintain proper wheel
mounting torque on the trailer. Be sure to use only the
fasteners matched to the cone angle of the wheel. Proper
procedure for attachment of the wheels is as follows:
1. Start all wheel lug nuts by hand.
2. Torque all lug nuts in sequence. See Figure 5. DO NOT
torque the wheel lug nuts all the way down. Tighten
each lug nut in 3 separate passes as defined by Table 4.
3. After first road use, retorque all lug nuts in sequence.
Check all wheel lug nuts periodically.
NOTE
NEVER use an pneumatic air gun to
tighten wheel lug nuts.
DCA-400SSK — TRAILER SAFETY GUIDELINES
Figure 5. Wheel Lug Nuts Tightening Sequence
PAGE 18 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)
NOTE:
LIGHTS ARE ORIENTED FROM THE DRIVER’S SEAT
DCA-400SSK — TRAILER-WIRING DIAGRAM
DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 19
gnitoohselbuorTekarBcirtcelE.5elbaT
motpmyS esuaCelbissoP noituloS
tnettimretnIrosekarBoN
sekarB
?seriwnekorbrostiucricnepoynA.tcerrocdnadniF
?stiucrictrohsynA.tcerrocdnadniF
?rellortnocytluaF.tcerrocdnatseT
?snoitcennocesoolynA.riaperdnadniF
?eruceseriwdnuorG.erucesdnadniF
sekarBrosekarBkaeW
ediSenOotlluP
?sgninilrostengamnolioroesaerG.ecalperronaelC
?dedorrocsnoitcennoCtcerrocdnanaelC
.noisorrocfoesuac
?devoorgroderocssmurdekarB.ecalperroenihcaM
?dezinorhcnyssekarB.tcerroC
sekarBgnikcoLrotneb,esoolstnenopmocekarB
?nekorb
.stnenopmocecalpeR
?dnuor-fo-tuosmurdekarB.ecalpeR
sekarBysioN?detacirbulmetsyS.etacirbuL
?tcerrocstnenopmocekarB.tcerrocdnaecalpeR
sekarBgniggarD?detsujdaleehwehtfosgniraeB.tsujdA
DCA-400SSK TRAILER-BRAKE TROUBLESHOOTING
PAGE 20 DCA-400SSK PARTS AND OPERATION MANUAL (STD) REV. #3 (09/17/01)
gnitoohselbuorTekarBciluardyH.6elbaT
motpmyS esuaCelbissoP noituloS
sekarBoN?deknikronekorbenilekarB.ecalperroriapeR
otlluPsekarBrosekarBkaeW
ediSenO
?dezalggninilekarB.ecalperrohsinrubeR
?dedaolrevoreliarT.thgiewtcerroC
?devoorgroderocssmurdekarB.ecalperroenihcaM
?tcerrocerusserperiT.yllauqeseritllaetalfnI
?elxaemasehtnodehctamnuseriT.serithctaM
sekarBgnikcoL?nekorbrotneb,esoolstnenopmocekarB.stnenopmocecalpeR
?dnuor-fo-tuosmurdekarB.ecalpeR
sekarBysioN?detacirbulmetsyS.etacirbuL
?tcerrocstnenopmocekarB.tcerrocdnaecalpeR
sekarBgniggarDthgirnirotcerrocssenkcihtgninilekarB
?noitisopgnorw
dnaseohswenllatsnI
.sgninil
?diulftcerrocrodiulfekarbhguonEstraprebburecalpeR
.diulf4todhtiwllif
DCA-400SSK TRAILER-BRAKE TROUBLESHOOTING
/